Aluminum alloy fin material for heat exchanger and method of production of same and method of production of heat exchanger by brazing fin material

ABSTRACT

An aluminum alloy fin material for a heat exchanger having suitable strength before brazing enabling easy fin formation, having high strength after brazing, having a high thermal conductivity (electrical conductivity) after brazing, and having superior sag resistance, erosion resistance, self corrosion prevention, and sacrificial anode effect, a method of production of the same, and a method of production of a heat exchanger using the fin material are provided, that is, an aluminum alloy fin material having a chemical composition of Si: 0.7 to 1.4 wt %, Fe: 0.5 to 1.4 wt %, Mn: 0.7 to 1.4 wt %, and Zn: 0.5 to 2.5 wt %, Mg as an impurity limited to 0.05 wt % or less, and the balance of unavoidable impurities and Al, and having a tensile strength after brazing of 130 MPa or more, a yield strength after brazing of 45 MPa or more, a recrystallized grain size after brazing of 500 μm or more, and an electrical conductivity after brazing of 47% IACS or more, a method of producing an aluminum alloy fin material comprising cold rolling/annealing/cold rolling/annealing/cold rolling a thin slab continuously cast by a twin-belt system from a melt of the above composition under predetermined conditions, and a method of production of a heat exchanger comprising cooling the fin material at a predetermined rate after brazing heating.

TECHNICAL FIELD

The present invention relates to an aluminum alloy fin material for aheat exchanger and a method of production of the same and a method ofproduction of a heat exchanger by brazing a fin material.

BACKGROUND ART

An aluminum heat exchanger is comprised of an aluminum alloy finmaterial brazed to an aluminum material forming working fluid passagesand the like. To improve the performance characteristics of the heatexchanger, as basic characteristics of this aluminum alloy fin material,a sacrificial anode effect has been demanded in order to preventcorrosion of the material forming the working fluid passages. Further,to prevent deformation due to high-temperature brazing heating andpenetration of the brazing material, a superior sag resistance anderosion resistance have been demanded.

The fin material, in order to satisfy the above basic characteristics,has Mn and Fe added to it. Recently, however, effort has been focused onthe production process and aluminum alloy fins for heat exchangers witha low tensile strength before brazing and a high tensile strength afterbrazing have been developed.

Japanese Patent Publication (A) No. 2005-220375 discloses a method ofproduction of an aluminum alloy fin for a heat exchanger having atensile strength before brazing of 240 MPa or less and a tensilestrength after brazing of 150 MPa or more comprising pouring a meltcontaining Si: 0.8 to 1.4 wt %, Fe: 0.15 to 0.7 wt %, Mn: 1.5 to 3.0 wt%, and Zn: 0.5 to 2.5 wt %, limiting Mg as an impurity to 0.05 wt % orless, and having a balance of normal impurities and Al, continuouslycasting a thin slab of a thickness of 5 to 10 mm by a twin-belt castingmachine, taking it up in a roll, then cold rolling it to a sheetthickness of 0.05 to 0.4 mm, process annealing the sheet at 350 to 500°C., and cold rolling it by a cold rolling reduction of 10 to 50% to afinal sheet thickness of 40 to 200 μm.

On the other hand, a method of production of a heat exchanger has beendeveloped which obtains a predetermined strength by defining the coolingrate after brazing when brazing an aluminum alloy fin material to analuminum material forming working fluid passages.

Japanese Patent Publication (A) No. 1-91962 discloses a method ofproduction of a heat exchanger taking note of the cooling rate afterbrazing heating and obtaining fins with a large tensile strength afterbrazing heating. Specifically, this is a method of production of a heatexchanger fabricating an Al heat exchanger by brazing during whichperforming the cooling from the brazing temperature to 350° C. by acooling rate of 100° C./min to 1000° C./min so as to obtain fins of alarge tensile strength.

Japanese Patent Publication (A) No. 2-142672 discloses a method ofproduction of an aluminum heat exchanger obtained by stacking tubes andfins, attaching headers to both ends of the tubes, and brazing thepieces using a chloride-based flux in the atmosphere, in dry air, orusing a fluoride-based non-corrosive flux in an inert gas atmosphere,said method of production of an aluminum heat exchanger characterized byusing a brazing sheet to fabricate tubes with an outer surface comprisedof an Al—Si-based alloy brazing material and with an inner surfacecomprised of an Al—Zn-based alloy and cooling from 500° C. to 200° C.after brazing them together at a rate of 50° C./min or more.

However, said Japanese Patent Publication (A) No. 2005-220375 has adescription regarding the electrical conductivity after brazing heating(thermal conductivity), but no description particularly relating to thecooling rate after the brazing heating can be found.

Further, said Japanese Patent Publication (A) No. 1-91962 and JapanesePatent Publication (A) No. 2-142672 disclose art defining the coolingrate after brazing heating to obtain a high strength fin material, butno description relating to the electrical conductivity (thermalconductivity) after the brazing heating can be found.

Further, recently, to make the fin material thinner, development of analuminum alloy fin material with not only the basic brazingcharacteristics, but also a high yield strength after brazing andsuperior in thermal conductivity after brazing has been hoped for.

DISCLOSURE OF THE INVENTION

An object of the present invention is to provide an aluminum alloy finmaterial for a heat exchanger having suitable strength before brazingenabling easy fin formation, having high strength after brazing, havinga high thermal conductivity (electrical conductivity) after brazing, andhaving superior sag resistance, erosion resistance, self corrosionprevention, and sacrificial anode effect, a method of production of thesame, and a method of production of a heat exchanger using the finmaterial.

To attain the above object, according to the present invention, there isprovided an aluminum alloy fin material for a heat exchanger having ahigh strength and heat transfer characteristic, erosion resistance, sagresistance, a sacrificial anode effect, and self corrosion preventioncharacterized by having a chemical composition of Si: 0.7 to 1.4 wt %,Fe: 0.5 to 1.4 wt %, Mn: 0.7 to 1.4 wt %, Zn: 0.5 to 2.5 wt %, Mg as animpurity limited to 0.05 wt % or less, and the balance of unavoidableimpurities and Al, and having a tensile strength after brazing of 130MPa or more, a yield strength after brazing of 45 MPa or more, arecrystallized grain size after brazing of 500 μm or more, and anelectrical conductivity after brazing of 47% IACS or more.

The method of producing the fin material of the present invention ischaracterized by pouring a melt having the chemical composition of saidfin material, continuously casting it by a twin-belt casting machine toa thin slab of a thickness of 5 to 10 mm, winding it up into a roll,performing first stage cold rolling to a sheet thickness of 1.0 to 6.0mm, performing primary intermediate annealing at 250 to 550° C.,performing second stage cold rolling to a sheet thickness of 0.05 to 0.4mm, performing secondary intermediate annealing at 360 to 550° C., andperforming final cold rolling at a reduction of 20 to 75% to a finalsheet thickness of 40 to 200 μm.

Further, the present inventors reached the conclusion that in order toobtain a fin material having a high yield strength after brazing andhaving superior thermal conductivity after brazing, along with theproduction process of the fin material itself, it is important tocontrol the cooling rate after brazing the fin material to the heatexchanger to a suitable range.

That is, the present invention provides a method of producing analuminum heat exchanger by brazing heating the fin material of thepresent invention characterized by cooling in the temperature range fromat least the brazing temperature after said brazing heating to 400° C.at a cooling rate of 10 to 50° C./min.

The aluminum alloy fin material for a heat exchanger of the presentinvention defines the composition and yield strength after brazing,recrystallized grain size after brazing, and electrical conductivityafter brazing, so can ensure a high strength and superior heat transfercharacteristics, erosion resistance, sag resistance, sacrificial anodeeffect, and self corrosion prevention.

The method of production of the fin material of the present inventionuses a melt of the chemical composition of the fin material of thepresent invention to obtain a thin slab by a twin-belt casting machineand cold rolls/anneals/cold rolls/anneals/cold rolls it so as to producea fin material provided with the above characteristics.

The method of production of a heat exchanger of the present inventiondefines the cooling rate after brazing the fin material of the presentinvention to cause the precipitation of Al—Mn precipitates andAl—(Fe,Mn)—Si-based precipitates, so can achieve a high electricalconductivity after brazing.

BEST MODE FOR CARRYING OUT THE INVENTION

The reasons for limiting the chemical composition of the aluminum alloyfin material for a heat exchanger of the present invention will beexplained next.

[Si: 0.7 to 1.4 wt %]

Si together with Fe and Mn forms submicron level Al—(Fe,Mn)—Si-basedcompounds during brazing, increases the strength, and at the same timedecreases the amount of solid solution of Mn to increase the thermalconductivity (electrical conductivity). If the content of Si is lessthan 0.7 wt %, this effect is not sufficient, while if over 1.4 wt %,the fin material is liable to melt during brazing. Therefore, Si contentis limited to 0.7 to 1.4 wt %. Preferably the Si content is 0.8 to 1.2wt %.

[Fe: 0.5 to 1.4 wt %]

Fe together with Mn and Si forms submicron level Al—(Fe,Mn)—Si-basedcompounds during brazing, increases the strength, and at the same timedecreases the amount of solid solution of Mn to increase the thermalconductivity (electrical conductivity). If the content of Fe content isless than 0.5 wt %, the strength deteriorates, so this is notpreferable. If over 1.4 wt %, coarse Al—(Fe,Mn)—Si-based precipitatesare formed during the casting of the alloy and the production of sheetmaterial becomes difficult. Therefore, the Fe content is limited to 0.5to 1.4 wt %. Preferably the Fe content is 0.5 to 1.2 wt %.

[Mn: 0.7 to 1.4 wt %]

Mn together with Fe and Si precipitates as submicron levelAl—(Fe,Mn)—Si-based compounds in a high density during brazing andimproves the strength of the alloy material after brazing. Further, thesubmicron level Al—(Fe,Mn)—Si-based precipitate has a strongrecrystallization inhibiting action, so the recrystallized grainsbecomes coarse ones of 500 μm or more and the sag resistance and erosionresistance are improved. If Mn is less than 0.7 wt %, this effect isinsufficient, while if over 1.4 wt %, coarse Al—(Fe,Mn)—Si-basedprecipitates are formed during casting of the alloy and production ofthe sheet material becomes difficult, the amount of solid solution of Mnincreases, and the thermal conductivity (electrical conductivity)deteriorates. Therefore, the Mn content is limited to 0.7 to 1.4 wt %.Preferably the Mn content is 0.8 to 1.3 wt %.

[Zn: 0.5 to 2.5 wt %]

Zn lowers the potential of the fin material and gives a sacrificialanode effect. If the content is less than 0.5 wt %, this effect is notsufficient, while if over 2.5 wt %, the self corrosion prevention of thematerial deteriorates. In addition, due to the solid solution of Zn, thethermal conductivity (electrical conductivity) deteriorates. Therefore,the Zn content is limited to 0.5 to 2.5 wt %. Preferably the Zn contentis 1.0 to 2.0 wt %.

[Mg: 0.05 wt % or less]

Mg is an impurity which influences brazeability and, if the content isover 0.05 wt %, is liable to impair the brazeability. Especially in thecase of fluoride-based flux brazing, the flux ingredient, that is, thefluorine (F), and the Mg in the alloy easily react and MgF₂ and othercompounds are formed. Due to this, the absolute amount of fluxeffectively acting at the time of brazing becomes insufficient andbrazing defects easily occur. Therefore, the Mg content is limited to0.05 wt % or less.

Regarding impurity ingredients other than Mg, Cu makes the potential ofthe material more precious, so is preferably limited to 0.2 wt % orless, while Cr, Zr, Ti, and V, even in trace amounts, cause thecoefficient of thermal conductivity of the material to remarkablyreduce, so the total content of these elements is preferably limited to0.20 wt % or more.

Next, the reasons for limitation of the conditions in a method ofproduction of an aluminum alloy fin material for a heat exchanger of thepresent invention will be explained.

[Continuously Casting Thin Slab of Thickness of 5 to 10 mm by Twin-BeltCasting Machine]

The twin-belt casting method is a continuous casting method comprisingpouring a melt between water cooled rotary belts facing each other inthe vertical direction, solidifying the melt by cooling from the beltsurfaces to obtain a slab, and continuously pulling out the slab fromthe opposite side of the belts from the pouring side and winding it upin a coil.

In the method of production of the present invention, the thickness ofthe casting slab is limited to 5 to 10 mm. With this thickness, thesolidification rate of the center part of the sheet thickness is so fastthat it is possible to obtain a fin material with few coarse compoundsand with a large crystal grain size and superior properties afterbrazing under the condition of a uniform structure and a composition inthe scope of the present invention.

If the thickness of the thin slab formed by the twin-belt castingmachine is less than 5 mm, the amount of aluminum passing through thecasting machine per unit time becomes too small and casting becomesdifficult. Conversely, if the thickness is over 10 mm, winding by a rollbecomes impossible, so the range of the slab thickness is limited to 5to 10 mm.

Note that the casting speed during solidification of the melt ispreferably 5 to 15 m/min and solidification preferably is completed inthe belts. If the casting speed is less than 5 m/min, the casting takestoo much time and the productivity reduces, so this is not preferable.If the casting speed is over 15 m/min, the aluminum melt cannot besupplied fast enough and obtaining a predetermined shape of a thin slabbecomes difficult.

Under the above casting conditions, the slab cooling rate(solidification rate) at a position of ¼ thickness of the slab duringcasting is 20 to 150° C./sec or so. By the melt solidifying with acomparatively fast cooling rate in this way, in the scope of thechemical composition of the present invention, the size of theintermetallic compounds such as Al—(Fe,Mn)—Si precipitating at the timeof casting can be controlled to 1 μm or less and the amounts of Fe, Si,Mn, and other elements in the matrix as solid solution can be increased.

[First Stage Cold Rolling to Sheet Thickness of 1.0 to 6.0 mm]

Next, to obtain a sufficient softened state in the primary processannealing and to sufficiently cause the precipitation of Si, Fe, Mn, andother solid solution elements in the matrix, the sheet thickness afterthe first stage cold rolling is limited to 1.0 to 6.0 mm. If a sheetthickness thicker than 6.0 mm, the effect is not sufficient, while ifless than 1.0 mm, edge cracking etc. occur at the time of the firststage cold rolling and the rollability otherwise falls. Further, gaugecontrol is necessary to obtain a balance between the reduction of thesubsequent second stage cold rolling and the reduction of the final coldrolling.

[Primary Intermediate Annealing at 250 to 550° C.]

The holding temperature of the primary intermediate annealing is limitedto 250 to 550° C. If the holding temperature of the primary intermediateannealing is less than 250° C., a sufficiently softened state cannot beobtained. If the holding temperature of the primary intermediateannealing is over 550° C., Si, Fe, Mn, and other solid solution elementsin the matrix will not sufficiently precipitate and the thermalconductivity after brazing heating (electrical conductivity) willreduce.

The holding time of the primary intermediate annealing does notparticularly have to be limited, but making it a range of 1 to 5 hoursis preferable. If the holding time of the primary intermediate annealingis less than 1 hour, the temperature of the coil as a whole remainsuneven and a uniform microstructure may not be obtained in the sheet, sothis is not preferred. If the holding time of the primary intermediateannealing is over 5 hours, the treatment takes too much time and theproductivity reduces, so this is not preferable.

The heating rate and cooling rate at the time of the primaryintermediate annealing do not particularly have to be limited, butmaking them 30° C./hr or more is preferable. If the heating rate andcooling rate at the time of the primary intermediate annealing is lessthan 30° C./hr, the treatment takes too much time and the productivityreduces, so this is not preferable.

The temperature of the first intermediate annealing by the continuousannealing furnace is preferably 400 to 550° C. If less than 400° C., asufficiently softened state cannot be obtained. However, if the holdingtemperature is over 550° C., the Si, Fe, Mn, and other solid solutionelements in the matrix will not sufficiently precipitate and the thermalconductivity (electrical conductivity) after the brazing heating willreduce.

The holding time of the continuous annealing is preferably within 5 min.If the holding time of the continuous annealing is over 5 min, thetreatment takes too much time and the productivity reduces, so this isnot preferable.

Regarding the heating rate and cooling rate at the time of continuousannealing, the rate of temperature rise is preferably 100° C./min ormore. If the rate of temperature rise during the continuous annealing isless than 100° C./min, the treatment takes too long and the productivityreduces, so this is not preferable.

[Second Stage Cold Rolling to Sheet Thickness of 0.05 to 0.4 mm]

Second stage cold rolling is necessary in order to obtain a sufficientlysoftened state in the subsequent secondary intermediate annealing and inorder to make the Si, Fe, Mn, and other solid solution elements in thematrix sufficiently precipitate.

If the sheet thickness is over 0.4 mm, this effect is not sufficient,while if less than 0.05 mm, it is no longer possible to control the coldrolling reduction in the subsequent final cold rolling. For this reason,the sheet thickness after second stage cold rolling is limited to 0.05to 0.4 mm.

[Secondary Intermediate Annealing at 360 to 550° C.]

The holding temperature of the secondary intermediate annealing islimited to 360 to 550° C. If the holding temperature of the secondaryintermediate annealing is less than 360° C., a sufficiently softenedstate cannot be obtained. However, if the holding temperature of thesecondary intermediate annealing is over 550° C., the Si, Fe, Mn, andother solid solution elements in the matrix will not sufficientlyprecipitate, the thermal conductivity (electrical conductivity) afterthe brazing heating will reduce, the recrystallization inhibiting actionduring brazing will weaken, the recrystallized grain size will becomeless than 500 μm, and the sag resistance and erosion resistance at thetime of brazing will deteriorate.

The holding time of the secondary intermediate annealing does notparticularly have to be limited, but making it a range of 1 to 5 hoursis preferable. If the holding time of the secondary intermediateannealing is less than 1 hour, the temperature of the coil as a wholeremains uneven and a uniform microstructure may not be obtained in thesheet, so this is not preferred. If the holding time of the secondaryintermediate annealing is over 5 hours, the treatment takes too muchtime and the productivity reduces, so this is not preferable.

The heating rate and cooling rate during the secondary intermediateannealing do not particularly have to be limited, but making them 30°C./hr or more is preferable. If the heating rate and cooling rate duringthe secondary intermediate annealing is less than 30° C./hr, thetreatment takes too much time and the productivity reduces, so this isnot preferable.

[Final Cold Rolling at Cold Reduction of 20 to 75% To Final SheetThickness of 40 to 200 μm]

<Cold Reduction: 20 to 75%>

If the cold reduction in the final cold rolling is less than 20%, thereis little strain energy accumulated by the cold rolling and therecrystallization will not be completed in the process of heating duringbrazing, so the sag resistance and erosion resistance will reduce. Ifthe cold reduction is over 75%, the product strength will become toohigh and obtaining the predetermined fin shape when shaping the finmaterial will become difficult. Therefore, the cold reduction in finalcold rolling is limited to 20 to 75%.

<Final Sheet Thickness: 40 to 200 μm>

If the sheet thickness of the fin material is less than 40 μm, thestrength of the heat exchanger is insufficient. Further, the conductionof heat in the air becomes low. If the sheet thickness of the finmaterial is over 200 μm, the weight of the heat exchanger becomeslarger.

The sheet material produced by the method of production of an aluminumalloy fin material of the present invention is generally slit topredetermined widths, then corrugated and alternately stacked with flattubes made of a material for working fluid passages, for example, cladsheet consisting of 3003 Alloy coated with a brazing material etc. andbrazed together so as to obtain a heat exchanger unit.

The reasons for limitation of the production conditions in the method ofproduction of a heat exchanger of the present invention will beexplained next.

[Cooling in Temperature Range from at Least Brazing Temperature afterBrazing Heating to 400° C. by Cooling Rate of 10 to 50° C./min]

The brazing of the aluminum heat exchanger is generally performed at600° C. or so.

The material must be cooled in the temperature range from at least thebrazing temperature after brazing heating to 400° C. by a cooling rateof 10 to 50° C./min. Preferably the material is cooled in thetemperature range from at least the brazing temperature after brazingheating to 300° C. by a cooling rate of 10 to 50° C./min. Morepreferably the material is cooled in the temperature range from thebrazing temperature after brazing heating to 200° C. by a cooling rateof 10 to 50° C./min.

In this way, in the fin material of the present invention, the slowerthe cooling rate after the brazing heating, the greater the amount ofprecipitation of the Al—Mn precipitates and Al—(Fe,Mn)—Si-basedprecipitates, so an electrical conductivity after brazing of 47% IACS ormore can be achieved. If the cooling rate after brazing is less than 10°C./min, the productivity of the heat exchanger remarkably reduces. Ifthe cooling rate after brazing is over 50° C./min, an electricalconductivity after brazing of 47% IACS or more is difficult to achieve.Further, if the cooling rate is within a range of 10 to 50° C./mincompared with a cooling rate after brazing of 50° C./min or more, a finmaterial with a high tensile strength after brazing and yield strengthcan be obtained.

EXAMPLES

Below, examples of the present invention will be explained in comparisonwith comparative examples.

First Embodiment

As invention examples and comparative examples, the alloy melts of thecompositions of the alloy Nos. 1 to 9 shown in Table 1 were produced,passed through ceramic filters, and poured into twin-belt castingmachines to obtain slabs of thicknesses of 7 mm by a casting speed of 8m/min. The cooling rates during solidification of the melts at ¼ of theslab thickness was 50° C./sec. The thin slabs were cold rolled to 4 mm,heated at a heating rate of 50° C./hr, held at 400° C. for 2 hours, thencooled at a cooling rate of 50° C./hr down to 100° C. for primaryintermediate annealing. Next, the sheets were cold rolled to 120 μm,heated at a heating rate of 50° C./hr, held at 400° C. for 2 hours, thencooled by a cooling rate of 50° C./hr down to 100° C. for secondaryintermediate annealing. Next, the sheets were cold rolled to obtain finmaterials of a thickness of 60 μm.

TABLE 1 (First Embodiment: Differences due to Chemical Composition)Sheet Fin Cast- Chemical composition (wt %) Work thickness material No.ing Alloy Si Fe Cu Mn Mg Zn Ti hardening (μm) Ex. 1 B 1 0.88 0.55 0.011.14 0.000 1.43 0.010 H16 60 2 B 2 0.93 0.91 0.02 0.90 0.010 1.47 0.010H16 60 3 B 3 0.90 0.73 0.02 1.10 0.010 1.50 0.010 H16 60 Comp. 4 B 40.58 0.70 0.02 1.09 0.007 1.48 0.007 H16 60 Ex. 5 B 5 1.62 0.80 0.020.80 0.007 1.50 0.007 H16 60 6 B 6 0.91 0.35 0.02 1.05 0.007 1.48 0.007H16 60 7 B 7 0.90 1.80 0.02 1.21 0.007 1.50 0.007 8 B 8 0.89 0.80 0.020.51 0.007 1.46 0.007 H16 60 9 B 9 0.87 0.70 0.02 1.72 0.007 1.52 0.007H16 60 10 D 10 0.97 0.51 0.01 1.21 0.010 1.58 0.010 H14 60 Beforebrazing After brazing heating Fin (H mat.) Braze- Grain size TS PS Elec.cond. material No. TS (MPa) E1 (%) ability (μm) (MPa) (MPa) (% IACS) Ex.1 208 1.9 G  800 135 55 47.2 2 207 1.2 G 2200 133 51 48.2 3 209 1.0 G3000 133 53 47.4 Comp. 4 195 1.4 G 1400 126 43 47.6 Ex. 5 P No good dueto erosion 6 200 1.6 G 1700 129 47 46.1 7 No good due to giant crystalsduring casting 8 195 1.4 G  800 123 43 48.5 9 248 0.9 G 3500 155 57 45.310 180 1.3 P  80 133 39 43.3 (Note) Underlined numerical values areoutside the scope of the present invention. Casting . . . B: Twin-beltcasting, D: DC casting TS: tensile strength, PS: yield strength, E1:elongation at break Brazeability: erosion resistance (605° C. × 5 min)

As a comparative example, an alloy melt of the composition of the alloyNo. 10 shown in Table 1 was prepared, cast by ordinary DC casting(thickness 560 mm, cooling rate during solidification of approximately1° C./sec), surface scalped, soaked, hot rolled, cold rolled (thickness90 μm), intermediate annealed (400° C.×2 hr), and cold rolled to producea fin material of a thickness of 60 μm by cold rolling.

The fin materials of the invention examples and comparative exampleobtained were measured by the following (1) to (3):

(1) Tensile properties before brazing

Tensile strength (MPa) and elongation at break (%) of the obtained finmaterials

(2) Tensile properties after brazing and grain size and conductiveproperties

[Brazing Heating Conditions]

The materials were heated at a heating rate of 20° C./min to 600 to 605°C., held there for 3 minutes, then cooled down to 200° C. by a coolingrate of 20° C./min, then taken out from the heating furnace and cooledto room temperature.

[Test Items]

[1] Tensile strength, yield strength (MPa)

[2] Grain size

The materials were electrolytically polished on their surfaces to exposethe grain structure by the Barker method, then were measured for thegrain size (μm) parallel to the rolling direction by the cross-sectionmethod.

[3] Electrical conductivity [% IACS] by the conductivity test methoddescribed in JIS-H0505

(3) Brazeability (erosion test)

Fin materials worked into a corrugated shape were placed on the brazingmaterial surfaces of brazing sheets (brazing material 4045 alloy cladrate 8%) of thicknesses of 0.25 mm coated with a non-corrosivefluoride-based flux (applied load of 215 g), heated by a heating rate of50° C./min up to 605° C. and held there for 5 minutes. After cooling,the materials were observed at their brazed cross-sections. Materialswhere the erosion of the grain boundaries of the fin material was minorwere judged as “good” (“G” symbol), while materials where the erosionwas extreme and the fin material remarkably melted were judged as “poor”(“P” symbol). Note that the corrugated shape was made as follows:

Corrugated shape: height 2.3 mm×width 21 mm×pitch 3.4 mm, 10 peaks

The measurement results are shown in Table 1.

From the results of Table 1, it is recognized that the fin materialsproduced by the method of the present invention are good in each of thetensile strength of the H material, the brazeability (erosionresistance), the tensile strength after brazing, the yield strengthafter brazing, and the electrical conductivity after brazing.

Fin Material No. 4 of a comparative example had a low Si content and alow tensile strength after brazing, yield strength after brazing, andelectrical conductivity after brazing.

Fin Material No. 5 of a comparative example had a large Si content and apoor erosion resistance in evaluation of the brazeability.

Fin Material No. 6 of a comparative example had a low Fe content and alow tensile strength after brazing and electrical conductivity afterbrazing.

Fin Material No. 7 of a comparative example had a large Fe content, hadgiant precipitates formed during casting, had cracks formed during coldrolling, and failed to give a fin material.

Fin Material No. 8 of a comparative example had a low Mn content and alow tensile strength after brazing and yield strength after brazing.

Fin Material No. 9 of a comparative example had a low Mn content, had ahigh tensile strength with H material (as cold rolled), and had a lowelectrical conductivity after brazing.

Fin Material No. 10 of a comparative example was a fin material obtainedby ordinary DC casting (thickness of 560 mm, solidification cooling rateof approximately 1° C./sec), surface scalping, soaking, hot rolling,cold rolling (thickness 90 μm), process annealing (400° C.×2 hr), andcold rolling. The yield strength after brazing was low, the grain sizeafter brazing was small, the brazeability (erosion resistance) wasinferior, and the electrical conductivity after brazing was low.

Second Embodiment

As invention examples and comparative examples, fin materials of alloyno. 2 obtained by the first embodiment were cooled by various coolingrates after the brazing heating.

That is, the materials were raised in temperature by a rate oftemperature rise of 20° C./min to 600 to 605° C., held there for 3minutes, then cooled to the intermediate temperature shown in Table 2(400° C. and 200° C.) at the cooling rates shown in Table 2 (60, 40, 30,20, and 10° C./min), then were taken out from the heating furnace andcooled to room temperature.

These brazed heated fin materials were measured for tensile strengthafter brazing, yield strength after brazing, and electrical conductivityafter brazing. The tensile test and measurement of the electricalconductivity were performed by similar methods as with the firstembodiment. The measurement results are shown in Table 2.

TABLE 2 (Second Embodiment: Differences Due to Cooling Rate AfterBrazing) Fin Cast- Chemical composition (wt %) Work material No. ingAlloy Si Fe Cu Mn Mg Zn Ti hardening Ex. 2 B 2 0.93 0.91 0.02 0.90 0.011.47 0.010 H16 11 B 2 0.93 0.91 0.02 0.90 0.01 1.47 0.010 H16 12 B 20.93 0.91 0.02 0.90 0.01 1.47 0.010 H16 13 B 2 0.93 0.91 0.02 0.90 0.011.47 0.010 H16 14 B 2 0.93 0.91 0.02 0.90 0.01 1.47 0.010 H16 Comp. 15 B2 0.93 0.91 0.02 0.90 0.01 1.47 0.010 H16 ex. 16 D 10 0.97 0.51 0.011.21 0.01 1.58 0.010 H14 10 D 10 0.97 0.51 0.01 1.21 0.01 1.58 0.010 H14After brazing heating Sheet Cooling Properties Fin thickness RateIntermediate TS PS Elec. cond. material No. (μm) (° C./min) temp. (° C.)(MPa) (MPa) (% IACS) Ex. 2 60 −20 200 133 51 48.2 11 60 −20 400 133 5147.3 12 60 −10 400 131 49 49.1 13 60 −40 200 133 50 47.4 14 60 −30 200132 50 47.3 Comp. 15 60 −60 200 131 48 46.6 ex. 16 60 −60 200 138 4343.5 10 60 −20 200 133 39 43.3 (Note) Underlined numerical values areoutside the scope of the present invention. Casting . . . B: Twin-beltcasting, D: DC casting TS: tensile strength, PS: yield strength

As shown in Table 2, Fin Material Nos. 2, 13, and 14 produced by themethod of the present invention heated by brazing under the coolingconditions after brazing heating of the method of the present inventionwere cooled in a temperature range from 600° C. to 200° C. by coolingrates of 20, 30, and 40° C./min, so it was recognized that good resultswere obtained in each of the tensile strength after the brazing heating,the yield strength after the brazing heating, the erosion resistanceafter the brazing heating, and the electrical conductivity after thebrazing heating.

Fin Material Nos. 11 and 12 produced by the method of the presentinvention heated by brazing under the cooling conditions after brazingheating of the method of the present invention were cooled in atemperature range from 600° C. to 400° C. by cooling rates of 10 and 20°C./min, so it was recognized that good results were obtained in each ofthe tensile strength after the brazing heating, the yield strength afterthe brazing heating, the erosion resistance after the brazing heating,and the electrical conductivity after the brazing heating.

Fin Material No. 15 of a comparative example had cooling conditionsafter brazing heating faster than the method of the present invention,so the electrical conductivity after the brazing was low.

Fin Material No. 16 of a comparative example was a DC cast slab rolledproduct and had cooling conditions after the brazing heating faster thanthe method of the present invention, so the yield strength and theelectrical conductivity after the brazing were low.

Fin Material No. 10 of a comparative example was a DC cast slab rolledproduct and had cooling conditions after the brazing heating in therange of the method of the present invention, but despite this the yieldstrength and the electrical conductivity after the brazing were low.

INDUSTRIAL APPLICABILITY

According to the present invention, there are providing an aluminumalloy fin material for a heat exchanger having suitable strength beforebrazing enabling easy fin formation, having high strength after brazing,having a high thermal conductivity (electrical conductivity) afterbrazing, and having superior sag resistance, erosion resistance, selfcorrosion prevention, and sacrificial anode effect, a method ofproduction of the same, and a method of production of a heat exchangerusing the fin material are provided.

1. An aluminum alloy fin material for a heat exchanger having a highstrength and heat transfer characteristic, erosion resistance, sagresistance, a sacrificial anode effect, and self corrosion preventioncharacterized by having a chemical composition of Si: 0.7 to 1.4 wt %,Fe: 0.5 to 1.4 wt %, Mn: 0.7 to 1.4 wt %, Zn: 0.5 to 2.5 wt %, Mg as animpurity limited to 0.05 wt % or less, and the balance of unavoidableimpurities and Al, and a tensile strength after brazing of 130 MPa ormore, a yield strength after brazing of 45 MPa or more, a recrystallizedgrain size after brazing of 500 μm or more, and an electricalconductivity after brazing of 47% IACS or more.
 2. An aluminum alloy finmaterial for a heat exchanger having a high strength and heat transfercharacteristic, erosion resistance, sag resistance, a sacrificial anodeeffect, and self corrosion prevention characterized by having a chemicalcomposition of Si: 0.7 to 1.4 wt %, Fe: 0.5 to 1.4 wt %, Mn: 0.7 to 1.4wt %, Zn: 0.5 to 2.5 wt %, Mg as an impurity limited to 0.05 wt % orless, and the balance of unavoidable impurities and Al, and a yieldstrength after brazing of 49 MPa or more, a recrystallized grain sizeafter brazing of 500 μm or more, and an electrical conductivity afterbrazing of 47% IACS or more.
 3. A method of producing an aluminum alloyfin material for a heat exchanger as set forth in claim 1 characterizedby pouring a melt having the chemical composition set forth in claim 1,continuously casting it by a twin-belt casting machine to a thin slab ofa thickness of 5 to 10 mm, winding it up into a roll, performing firststage cold rolling to a sheet thickness of 1.0 to 6.0 mm, performingprimary intermediate annealing at 250 to 550° C., performing secondstage cold rolling to a sheet thickness of 0.05 to 0.4 mm, performingsecondary intermediate annealing at 360 to 550° C., and performing finalcold rolling at a reduction of 20 to 75% to a final sheet thickness of40 to 200 μm.
 4. A method of production of an aluminum alloy finmaterial for a heat exchanger as set forth in claim 3 characterized byperforming the primary process annealing by a continuous annealingfurnace at a heating rate of 100° C./min or more and a holdingtemperature of 400 to 550° C. for a holding time of within 5 minutes. 5.A method of producing an aluminum heat exchanger by brazing heating thefin material as set forth in claim 1 characterized by cooling in thetemperature range from at least the brazing temperature after saidbrazing heating to 400° C. at a cooling rate of 10 to 50° C./min.
 6. Amethod of production of an aluminum heat exchanger as set forth in claim5 characterized by using a fluoride-based non-corrosive flux for joiningby brazing in an inert gas atmosphere.